Method of preventing wicking and moisture and vapor absorption and penetration in paperboard cartons, and cartons produced by such method



, R. J. HICKIN ETAL 3,198,416 METHOD OF PREVENTING WIGKING AND MOISTUREAND VAPOR Aug. 3, 1965 ABSORPTION AND PENETRATION IN PAPERBOARD CARTONS,AND CARTONS PRODUCED BY SUCH METHOD Filed Sept. 18, 1962 14 Sheets-Sheet1 all I NVENTORS ATTORNEY 1965 R. J. HICKIN ETAL 3,198,416

METHOD OF PREVENTING WICKING AND MOISTURE AND VAPOR ABSORPTION ANDPENETRATION IN PAPERBOARD CARTONS, AND CARTONS PRODUCED BY SUCH METHODFiled Sept. 18, 1962 14 Sheets-Sheet 2 II d u b I! a INVENTORS V na/n16BY ATTORNEY METHOD OF PREVENTING WICKING AND MOISTURE AND VAPORABSORPTION AND PENETRATION IN PAPERBOARD CARTONS, AND CARTONS PRODUCEDBY SUCH METHOD Filed Sept. 18, 1962 14 Sheets-Sheet 5 3, 1965 R. J.HlCKlN ETAL 3,198,416

a n a d" bl! ATTORNEY Aug. 3, 1965 R. J. HlCKlN ETAL METHOD OFPREVENTING WICKING AND MOISTURE AND VAPOR ABSORPTION AND PENETRATION INPAPERBOARD CARTONS AND CARTONS PRODUCED BY SUCH METHOD 14 Sheets-Sheet 4Filed Sept. 18, 1962 INVENTORS ATTORNEY Aug. 3, 1965 R. J. HlCKlN ETAL3,

METHOD OF PREVENTING WICKING AND MOISTURE AND VAPQR ABSORPTION ANDPENETRATION IN PAPERBOARD CARTONS, AND CARTONS PRODUCED BY sUcH METHODFiled Sept. 18, 1962 14 Sheets-Sheet 5 5 a d b F .2 I LA I f o /'79.Z\f/ 0 6/ I .5 F (I l 8 INVENTORS 4,4,; 2 W BY 5 ATTORNEY Aug. .3,1965 R. J. HlCKlN ETAL 3,193,416

METHOD OF PREVENTING WICKING AND MOISTURE AND VAPOR ABSORPTION ANDPENETRATION IN PAPERBQARD canons, AND GARTONS rnonucsn BY SUCH METHODFiled Sept. 18, 1962 14 Sheets-Sheet 6 Aug. 3, 1965 R. J. HlCKlN ETAL3,198,416

METHOD OF PREVENTING WICKING AND MOISTURE AND VAPOR AB ORPTION ANDPENETRATION IN PAPERBOARD GARTONS, AND CARTONS PRODUCED BY sUcH METHODFiled Sept. 18, 1962 14 Sheets-Sheet 7 Lllll EL 5 19;. EM i /2- g I :l4; 5 INVENTORS I i 5 led 149 E M .zl 2

i E Au. BY 7 ATTORNEY Aug. 3, 1965 R. J. HICKIN ETAL 3,198,415

METHOD OF PREVENTING WICKING AND MOISTURE AND VAPOR ABSORPTION ANDPENETRATION IN PAPERBOARD CARTONS, AND CARTONS PRODUCED BY SUCH METHODl4 Sheets-Sheet 8 Filed Sept. 18, 1962 all d II 35 INVENTORS .306 WWWAug. 3, 1965 R. J. HICKIN ETAL METHOD OF PREVENTING WICKING AND MOISTUREAND VAPOR ABSORPTION AND PENETRATION IN PAPERBOARD CARTONS, ANDGAR'I'ONS PRODUCED BY SUCH METHOD Filed Sept. 18, 1962 14 Sheets-Sheet 9w m M ATTORNEY Aug. 3, 1965 J. HICKIN ETAL 3,198,416

METHOD OF PREVENTING WICKING AND MOISTURE AND VAPOR ABSORPTION ANDPENETRATION IN PAPERBOARD CARTONS, AND CARTONS PRODUCED Filed Sept. 18.1962 BY SUCH METHOD 14 Sheets-Sheet 1O al cl v D id i f i a e ;3 a b Em"-54 25 an bl! I e r a a i i- .f r" E 3:; E f i 5V5 all :i i: 1 ii a 5% ii 6 i r :3 1 I '5 23 i 3,198,416 METHOD OF PREVENTING WICKING ANDMOISTURE AND VAPOR Aug. 3, 1965 R. J. HlCKlN ETAL ABSORPTION ANDPENETRATION IN PAPERBOARD CARTONS, AND CARTONS PRODUCED BY SUCH METHODFiled Sept. 18. 1962 14 Sheets-Sheet 11 3 m T. m V m ATTORNEY Aug. 3,1965 R. J. HICKIN ETAL 3,198,416

METHOD OF PREVENTING WICKING AND MOISTURE AND VAPOR AB ORPTION ANDPENETRATION IN PAPERBOARD CARTONS, AND CARTONS PRODUCED BY SUCH METHODl4 Sheets-Sheet 12 Filed Sept. 18, 1962 INVENTORS ATTORNEY A118. 1965 R.J. HICKIN ETAL 3,198,416

ING AND MOISTURE AND VA METHOD OF PREVENTING WICK POR ABSORPTIONETRATION IN ERBOARD CARTQ CART PRO CED BY SUCH ME D Filed Sept. 18. 196214 Sheets-Sheet 1s Aug. 3, '1965 R. J. HICKIN' ETAL METHOD OF PREVENTINGWICKING AND MOISTURE AND VAPOR ABSORPTION AND PENETRATION IN PAPERBOARDCARTONS, AND CARTONS PRODUCED BY SUCH METHOD 14 Sheets-Sheet 14 FiledSept. 18, 1962 F .0 V l I (-J I J a d 4 m w a w w 9 9 "0 W 0 a.

U r w M 4 d "d m W M r L. v. l..\ ry a Z x a a v .wlwkx m NJ u d UUnited States Patent 3,198,416 METHGD 0F PREVENTING WECKING AND MGiS-TURE AND VAPOR ABSORPTION AND PENE- TRATION IN PAPERBOARD CARTONS, ANDCARTUNS PRODUCED BY SUCH METHOD Robert J. Hickin, Seville, Frank W.Hackman, Wooster, and Sylvester M. Heinz, Rittman, Ohio, assignors toPackaging Corporation of America, Dover, Del, a corporation of DelawareFiled Sept. 18, 1962, Ser. No. 224,464 Claims. (Cl. 229-14) Thisinvention relates to the packaging art, and it has special reference tothe containers employed therein, particularly cartons of the foldedblank type made of paperboard and similar sheet material of a somewhatporous or bibulous nature, the ends of which cartons are usually closedand sealed by flaps relatively folded, and adhesively secured, injuxtaposed condition.

In the packaging of powdery, granular, and flaky materials in car-tonsof this general type it is practically impossible to prevent sitting ofthe contents thereof through voids in the end closures which are due toimperfect sealing of the end closure flaps. Also, as a result of suchimperfection, infestation of the carton contents is apt to occur, andsuch infestation poses a major problem particularly in the packaging offoodstuffs. Moreover, where such cartons are employed in the packagingof deliquescent or efl'lorescent materials or substances, or materialsor substances which would deteriorate because of absorption or loss ofmoisture, imperfect sealing of the cartons will result in spoilage ofthe carton contents.

Various packaging expedients have been resorted to for correcting thesefaults of sifting, infestation, and absorption or loss of moisture, suchas overwraps, and overall exterior plastic, or Wax, coatings for theflap-sealed cartons, and the car-tons have also been provided withinterior bag-like containers to produce packages of the so-calledbag-in-box type in which the bags containing the contents of thepackages are hermetically closed and sealed But, in the packaging art aprimary consideration of the packager is to obtain cartons which, asunitary structures, will, when closed and sealed by the relativelysimple line-production closing and securing of the end closure flaps,produce packages which are sift-proof, infestationproof and proofagainst the entrance or loss of moisture. Obviously, the use of suchcar-tons can materially reduce packaging costs not only in respect tothe cost of the cartons themselves but also in respect to packaging lineoperation as compared to packaging practices employing the expedientshereinbefore referred to, as examples, all of which require additional,and relatively expensive, package-forming materials or elements, andadditional packaging line operations.

Moreover, with the possible exception of the bag-inbox, such expedients,even with their added costs, have beenfound in practice to givequestionable, or little if any, satisfaction in overcoming the packagefaults which they are designed to correct.

When an overwrap is used, and it may be either opaque and printed with acustomary display, or transparent to reveal the display rinted on theunderlying carton walls, sifting of the package contents may occurwithin the overwrap, or when the overwrap is broken away for access tothe carton the thus sifted contents will produce an objectionable spill.Moreover, when sifting occurs within a transparent overwrap it causesthe package to become unsightly by obscuring, or hazing-over, theprinted display on the underlying carton walls, and when an opaqueoverwrap is broken away the package becomes unsightly due to exposure ofthe usually bare, unlined or ice unde-corated exterior of the cartonwalls. Furthermore, where sifting occurs there could also be infestationand absorption or loss of moisture in the packaged goods unless thenature and seal of the overwrap are such as to prevent them, whichlatter is rarely the case.

As in the case of over'wraps, overall plastic or wax coatings are notonly expensive but are seldom wholly effective, due either to voidsoccurring by reason of faulty application of the coatings or to crackingor chipping which may occur as a result of shipping or handling.

The primary objection to the bag-in-box type of package is its cost andits handling during the pack-aging operation.

In accordance with the invention covered by Patent No. 3,007,376,granted November 7, 1 961, in which the present Robert I. Hickin isjoined with Daniel C. McCollough as an inventor, and in theirapplication for patent for Sealed Canton, filed January 17, 1961, SerialNo. 83,310, new Patent No. 3,140,809, which is a division of theapplication for said patent, a paperboard-carton package can be producedwhich, in'actual commercial production running into themillions ofcartons, has been found to properly meet all tight-package requirements,being siftproof and infestationaproof, and presenting an almost whollyehective moisture-vapor barrier.

In accordance with the said patented invention the carton is of thefolded blank type, preferably, but not nec essarily, made, commercially,from paperboard sheet stock the ultimate inner face of which is providedwith a liner of grease and moisture-repellant material which may beeither of lamellar sheet form, or a coating, to provide a grease andmoisture-vapor barrier, the nature of such liner, and indeed itspresence or absence, being dictated by the inherent characteristics ofthe commodity to be packaged. The carton is closed at its ends byconventional end-closure flaps folded into juxtaposed assembly andadhesively secured, and edges of the flaps in areas or zones where voidsmight, and otten do, occur have applied to them strip-like deposits of anormally non-setting, plastic adhesive substance which serves to closesuch possible voids and seal the carton against sifting and infest-ationand supplement, or'nearly complete, the elfectiveness of themoisture-vapor barrier. in cartons of the type in which certain of theend-closure flaps are provided with Van Buren ears which are folded overupon and secured to adjacent side walls, the strip-like deposits ofnonhardening plastic adhesive are applied to flap edges in areasadjacent to the folding scores of such ears and hence, when the ears arefolded over upon and secured to the adjacent side walls, the plasticadhesive will not only be covered and concealed by the ears but will beforced, by folding of the ears, into any voids which may be present,

As is well known, a folded blank carton is so designed that, when itsblank is folded flat to provide its ultimate tubular form, one terminaledge of the blank, which is provided with a glue flap, is secured to theother terminal edge of the blank by such glue flap. Thus, although theblank may be provided with a liner which is both grease proof andmoisture and vapor repellent, the cut, or raw, terminal edge of the glueflap or the said other terminal edge of the blank (depending, primarily,upon whether the glue flap is secured as an inside or an outside glueflap, respectively), presents an area of unprotected paperboard which,although relatively small, may absorb or wick grease fromgreasy or oilypackaged commodities, such, for example, as cake mixes, fried potatoes,and others, with the result that the grease is carried by absorption,saturation or penetration, into adjacent areas of the carton walls, andoften to the outer surface thereof where it is unsightly and reduces thesales appeal of. the package, and may also at least partially obscure ordamage the usual printed display on the carton wall. Also, the raw edgeof the glue flap, or of the said terminal edge of the blank, presents anunprotected, bibulous area which may to some extent defeat themoisture-vapor tightness of the package.

It will be understood that the terminal edges referred to are the longedges of the flap, and blank, and although the short edges at the endsof the flap and blank are also cut, raw edges they are not so subjectedto absorption as the longedges for the reason that they can be sotightly contacted by the sealed end flaps as to preclude objectionablewicking contact with the carton contents.

Various expedients have in .the past been suggested to cure thesedefects of absorption or wicking in such areas, and of moisture andvapor penetration, but those now known are thought to be either tooineificient, 'or too costly from the carton manufacturing standpoint, tobe proper for practical application.

The object of the present invention is, therefore, to provide a methodand means for correcting this fault in cartons, and the cartonsembodying the improvements resulting therefrom.

To this end the invention comprises a method of preventing or arrestingthe passage of moisture or vapor, and the absorption or wicking ofgrease or oil, into bibulous portions of paperboard cartons,particularly at the joined edges of the blanks therefor and thence to acarton wall, which comprises the steps of removing, or skiving, from anedge-adjacent portion of the carton blank, which is ultimatelyassociated with the inner wall surface of the carton, or specificallyfrom said glue flap, an increment of the thickness of the paperboard ofsaid blank to thereby expose the paper fibers of the blank, applying tosaid edge portion and to said exposed fibers, preferably during theoperation of folding and gluing the blank, a substance preferably of anadhesive nature, which has such properties as will enable it toimpregnate, or provide a sealing barrier on, the exposed fibers to anextent sur'ficient to arrest the passage of moisture and vapor andprevent the absorption or wicking of grease or oil, and adhering suchedge portion, or specifically the glue fiap, to a complemental cartonwall preferably with the treated fibrous area of said edge portion injuxtaposition to said wall; and the invention comprises, also, numerousrefinements in relation to preparation of such edge portion forreception of the impregnatingorsealing substance, and relativedisposition of parts of the edge portion subsequent to application ofthe said substance, such as the location of the skived area withrelation to said edge portion, the depth and width of the skivedincrement and its surface characteristics, and, in some instances, thefolding of the edge portion adjacent to, or including, such skived areaprior to its adhesive attachment to the complemental carton wall; and,furthermore, the invention comprises the application of the skivingprinciple to parts of cartons other than a wall edge portion or a glueflap, or similar secured element, whereby a relatively thin, foldablesealing flap or flap extension may be produced, all as will be explainedhereinafter more particularly and finally claimed.

In the accompanying drawings illustrating the invention, in the severalfigures of which like parts are similarly designated,

FIG. 1 shows, in plan, the outer face of a carton blank embodying onemode of practicing the invention, a portion of the blank being brokenaway,

FIG. 2 is a greatly enlarged fragmentary section taken on the line 2-2of FIG. 1,

FIG. 3 shows, to a reduced scale, in perspective, the inner face of theblank of FIG. 1 with its glue flap fiatfolded and the second fold of theblank initiated,

FIG. 4 shows a carton erected from the blank of FIG. 1 with the endflaps at one end closed and sealed and those at the other end open,

FIG. 5 shows, in plan, the outer face of a carton blank different fromthat shown in FIG. 1, and illustrating another mode of practicing theinvention, a portion of the blank being broken away,

FIG. 6 is a fragmentary plan view of edge-adjacent parts of the blank ofFIG. 5 with the skived liner portion of the flue flap folded over andsecured to such flap,

FIG. 7 is an edge view of the flat-folded and glued blank of FIG. 5,

FIG. 8 is a greatly enlarged fragmentary section taken on the line 8-8of FIG. 5,

FIG. 9 is a view similar to FIG. 8 but showing the skived liner portionof the glue flap folded over and secured to such flap, substantially asillustrated in FIG. 6,

FIG. 10 is a view similar to FIG. 8 but differing therefrom in that theliner is formed by a coating applied to the inner face of the board ofthe blank, whereas in FIG. 8 the liner is shown as a lamellar sheet,

FIG. 11 is a view similar to FIG. 9 but related to the showing of FIG.10,

FIG. 12 is a view similar to FIG. 5 but showing another modification ofthe skiving practice of the invention,

FIG. 13 is a greatly enlarged fragmentary section taken on the line 1313of FIG. 12,

FIG. 14 is a view similar to FIG. 13 but showing the skived portion ofthe glue flap folded back upon itself,

FIG. 15 is a fragmentary section similar to that of FIG. 14 but showinga completed glue joint between-the glue flap and an adjacentcomplemental carton wall,

FIG. '16 is a view similar to FIG. 13 but showing the depth of theskived area extending to the liner sheet or layer of the paperboard ofthe blank,

FIG. 17 is a view similar to FIG. 16 but showing the liner sheet orlayer folded upon itself and secured,

FIG. 18 is a fragmentary perspective view of one end of a carton madefrom a blank having the structural characteristics of that shown inFIGS. 12 to 15,

FIG. 19 is a view similar to FIGS. 5 and 12 but showing a furthermodified embodiment of the invention in which the skived area of theglue flap is disposed adjacent to but inwardly of the longitudinal edgeof such flap, to thus provide adjacent'to both edges of the skivedchannel so formed coplanar areas of the flap for attachment to thecomplemental carton wall,

FIG. 20 is an enlarged fragmentary edge view of the right-hand portionof the blank of FIG. 19,

FIG. 21 is a view similar to FIG. 20, but reversed edgefor-edge, showingthe glue flap in-folded and attached to the complemental carton wall,

FIG. 22 is a fragmentary perspective view of one end of a carton formedfrom the blank of FIGS 19 to 21,

FIG. 23 is a view similar to FIGS. 5,. 12 and 19 but showing a blankembodying another modification of the invention in which the skivedportion of the glue flap providesan offstanding thin guard or lipportion preferably constituted in thickness by the paperboard liner,whether it be in the form of a lameliar sheet or a coating, forndirectadhesive union with the complemental carton wa FIG. 24 is a greatlyenlarged fragmentary edge view of the right-hand portion of FIG. 23,

FIG. 25 is a view similar to FIG. 24, but reversed edge-for-edge,showing the glue flap in-folded and it and its lip portion attached tothe complemental carton wall,

FIG. 26 is a fragmentary perspective view of one end of a carton madefrom the blankof FIG. 23,

FIG. 27 is a plan view of the outer face of a carton blank similar tothat of FIGS. 5, 12, 19 and 23 but embodying modification of certain ofthe end closure flaps to accommodate skiving to furnish thereon foldableex- ;iensions for inclusion in the sealing assembly of the end P FIG. 28is a veiw similar to FIG. 27 but showing the blank after performance ofthe flap-skiving operation,

FIGS. 29 and 30 are perspective views of the carton made from thefinished blank of FIG. 28; FIG. 29 ShQW- ing the two broad end flapsupstanding and FIG. 30 showing the broad end flap carrying the extensionfolded down with its extension bearing against the inner face of theother broad end flap in such association as to be sealingly foldedtherewith down against the previously folded broad flap,

FIG. 31 is a schematic view illustrating apparatus and method suitablefor performance of the skiving operation on blanks of any of the formsshown in FIGS. 1, 5, 12, 19, 23 and 27, and particularly on blanks ofthe FIG. 27 form to make the conversion thereof shown in FIG. 28,

FIG. 32 is a plan view of the inner face of a blank for forming apartitioned carton in which the partition element is provided as afrangible extension of the glue flap, the glue flap itself being skivedto form a wicking barrier in substantially the manner illustrated inFIG. 19 to 22,

FIG. 33 is a view similar to FIG. 32 but showing the first fold of theblank in which the glue flap and its frangible partition element areflat-folded against an adjacent broad side wall,

FIG. 34 is an exterior plan view of the completely flat-folded and gluedcarton blank of FIGS. 32 and 33,

FIG. 35 is an enlarged transverse section of the squaredup carton ofFIG. 34 showing the attached glue flap, and the partition elementsecured to the opposite broad side walls in the position assumed by itwhen the carton is squared up,

FIG. 36 is a schematic view illustrating, diagrammatically, a method andapparatus for folding and gluing the partitioned carton blank of FIGS.32 to 35 and for freeing the frangible partition element from the glueflap during such folding and gluing operation,

FIG. 37 is a view similar to FIG. 32 but showing the blank for apartitioned carton in which the frangible partition element is attachedto a wall panel rather than to a glue flap,

FIG. 38 shows the first fold of the elements of the blank of FIG. 37,

FIG. 39 shows the partition element secured to a carton side wall paneland freed along its line of fracture from the wall panel to which it wasoriginally attached, said last named panel being folded outwardly,

FIG. 40 shows the third fold of the blank in which the glue flap isbrought into position for securement thereto of the wall panel lastmentioned in relation to FIG. 39.

FIG. 41 shows the final fold of the blank with the said last mentionedwall panel secured to the glue flap,

FIG. 42 is an enlarged transverse section of the partitioned cartonsquared up from the folded blank of FIG. 41,

FIG. 43 is a schematic view similar to FIG. 36, but illustrating,diagrammatically, a method and apparatus for performing the folding andgluing operations on carton blanks of the type shown in FIGS. 37 to 41,

FIG. 44 is an enlarged fragmentary perspective view, with parts insection, showing a carton blank of the type illustrated in FIG. 1, butmodified as to details, and illustrating the application of a sealing orcalking compound beneath the Van Buren ears of the last-folded endclosure flap, such ears being shown in raised position,

FIG. 45 is a view similar to FIG. 44 but showing the Van Buren earsclosed down and sealed against the adjacent narrow side walls,

FIG. 46 is a sectional elevation taken substantially in the plane ofline 4646, FIG. 45, and showing the Van Buren ears in broken lines inraised position similar to the showing of FIG. 44.

FIG. 47 is a plan view showing the outer face of a carton blankgenerally similar to that of FIG. 1 but including structural andassembly modifications,

FIG. 48 is a view of the blank of FIG. 47 reversed face for face andshowing the first assembly fold,

FIG. 49 is a view similar to FIG. 48 but showing the second, final, fiatblank assembly fold, parts being broken away at one corner to showunderlying parts.

FIGS. 50, 51 and 52 are views essentially similar to FIGS. 47, 48 and49, respectively, but showing a further modification of the blank ofFIG. 1.

Preliminary to consideration of a detailed description of the variousembodiments of the invention herein disclosed, it should. be borne inmind that a factor of major importance in the production'of cartons,namely the cost factor, has been one of the primary considerations inthe development of the invention, and its novel features are of such anature as to make possible their embodiment in carton blanks of a widevariety of types and produced from accepted kinds of sheet material,specifically paperboard.

Also, in view of the fact that the invention is directed to the controlof wicking, or absorption, or penetration of moisture, vapor, grease oroil into raw edges of the paperboard exposed interiorly of the carton,it is preliminarily essential to the effective practice of theinventionthat the sheet stock from which the carton blanks are formed be providedwith a moisture, vapor and/or grease repellent liner layer on its facewhich forms the several interior surfaces of the carton. Such a linerlayer may comprise one or more sheets of glassine or similarsubstantially impervious or pergameneous stock laminated onto thepaperboard sheet, or it or provides a sub-surface impregnation of, thesheet. Moreover, in the interest of economy, this liner should form apart of the sheet stock from which the carton blanks are cut prior tothe cutting operation, thus avoiding the problems of blank registerwhich have in the past resulted from attempts to combine precut linearsheets with mating carton blanks.

It will be noted, as will be pointed out in more detail hereinafter,that in accordance with the invention the carton blanks having linerswhich, in effect, are integral parts thereof, and are coextensive inarea therewith, may be handled as integers and operated upon inaccordance with the invention during the blank folding and gluingoperation.

These refinements in composition'and handling of the blanks madepossible by the practice of the invention result in the production ofblanks embodying the protective features of the invention at onlyslightly increased cost, if any, over production of blanks lacking suchfeatures, and it will be understood that any such increase in cost willbe offset by the advantages obtained over cartons formed and producedfrom blanks made in accordance with presently accepted practices.

The primary object of the invention being, as hereinbefore pointed out,the protection of the raw or cut edges of the paperboard which areexposed interiorly of the carton and in contact with the cartoncontents, and particularly the longitudinal edge of a Wall panel or ofthe glue flap, it will be apparent that the practice of the invention isnot restricted to cartons of any particular style but is rather ofsubstantially general application.

Moreover, although a number of specific embodiments of, or modes ofpracticing, the invention are herein disclosed, and are shown inrelation to cartons formed from blanks of numerous accepted types, itwill be understood that, with a few exceptions, any of such embodimentsor modes can be employed, alternatively, with any selected types ofcartons so long as the blanks therefor lend themselves to the practice.

Furthermore, although in the majority of the cartons herein disclosedthe sealing of the end closure flaps may be relatively simple, it willbe understood that such sealing may embody the practice covered by theaforementioned Hickin and McCullough Patent No. 3,007,376, or mayinclude separately applied, or integral, sealing sheets adapted to begusset-folded with the end closure flaps, as shown, for example, in thepatents of Robson -No. 1,279,589, September 24, 1918, Benzon-PetersonNo. 2,795,364, June 11,1957, Turpin No. 2,996,235, August 15, 1961, andothers, or may have corner-sealing gusset means, as shown, for examplein the patents of Gannon et al. N0. 1,723,150, August 6, 1929, WesselmanNo. 2,107,096, February 1, 1938, Benzon-Peterson, above referred to, andothers. Also, various combinations of the sealing expedients of thesepatents may be made, and, if desired, at least one of the end closureflaps may be provided with so-called Van Buren ears, as shown in thepatents of Ash No. 1,223,232, April 17, 1917, Van Buren Nos. 1,863,259,1,863,260, 1,863,261, June 14, 1932 and others.

It will be noted that the blanks of all of the cartons shown in thedrawings as representative, merely, of styles in which the presentinvention may be embodied, are of the type formed from sheet material,such, preferably, as paperboard, suitably cut and scored in conventionalmanner to produce two broad side walls a and b, two narrow side walls 0and d, and a glue flap e. Also, the broad side walls a and b areprovided at their opposite ends end closure flaps a, a" and b, b,respectively, and the opposite ends of the narrow side walls 0 and d areprovided with end closure flaps c, c" and d, d", respectively.

Except for the forms of blanks shown in FIGS. 32 to 35, and FIGS. 39 to42, which have special attributes for provision of a partition member,and those shown in FIGS. 47 to 49, and FIGS. 50 to 52, which are of theoutside glue flap type, all of the blanks shown areof the type in whichthe glue flap e is attached to the outer longi tudinal edge of the broadside wall b and is foldable thereagainst during the gluing operation forattachment to the juxtaposed fiat-folded edge portion of the inner faceof the narrow side wall c, and hence is disposed interiorly of thefinished carton.

As indicated in all of the figures of the drawings, with the exceptionof FIGS. 10 and 11, the inner face of each of the blanks is providedwith a lamellar sheet or liner f which produces a barrier for oil,grease, moisture and vapor, but this liner need not be of lamellar sheetform but may be a surface, or impregnating, coating 1", as indicated inFIGS. 10 and 11.

In FIGS. 1 to 4, and 44 to 52, the blanks for the cartons are of thetype in which the end flaps of one of the broad side walls are providedwith Van Buren ears g, but it will be understood that the inclusion ofthis detail is, as hereinbefore indicated, optional, and has no directrelation to the particular mode of treatment of the carton wall panelsor glue flaps to provide their cut or raw edges with a barrier againstwicking and moisture and vapor penetration in accordance with theinvention.

Coming now to the several modes of practicing the invention asillustrated in the drawings, which, as hereinbefore mentioned, should beconsidered primarily as representative and not as excluding possiblemodifications, it will be seen that in FIGS. 1 to 4 the freelongitudinal edge of the glue flap e is skived on the outer face of theblank to produce a gradually sloping beveled or feather edge 1 whichpreferably terminates at, and does not extend into, the barrier layer orsheet This skiving removes'a predetermined increment of the thickness ofthe paperboard in an adequate area inwardly from the edge of the glueflap and exposes the bibulous fibres of the paperboard throughout sucharea, as indicated by stippling. The skiving may be performed by aknived cutting wheel, or a grinding wheel, or other appropriate abradingmeans, and the sitiving operation is preferably performed during theblank-folding and gluing operation, as hereinbefore vapor repellent (andthere are now many such adhesives commercially available in the categoryof natural and synthetic resin adhesives, and others), it will beapparent that this sealing of the raw or cut edge of the glue flap willmake the edge substantially impervious, and elfectively repellent, tooil, grease, moisture and vapor, and will provide the desired barrier atsuch edge to absorption or wicking of oil or grease from the cartoncontents and to passage of moisture and vapor.

Thus, with the interior of the carton protected by the barrier providedby the liner f, and the raw or cut edge of the glue flap sealed, asdescribed, the faults usually present in such a raw or cut edge areovercome and the entire interior of the carton is made effectivelyimpermeable.

If desired, a score 2 (FIG. 1) may be provided longitudinally of theglue flap 2 adjacent to the inner edge of the skived area in order tofacilitate and insure flat-gluing, or adhesion, of this skived areaagainst the inner face of the narrow side wall 0, see FIG. 4.

Having reference particularly to FIG; 4, it will be ap-- parent, ashereinbefore intimated, that the short, transverse ends of the glue flape which present raw, cut edges are not treated for the prevention ofwicking or penetration of moisture or vapor, but when the carton isclosed and sealed these edges are in such intimate contact with theflaps c, c", which are held closed by the adhesively afiixed fiaps b, aand b", a", that any entrance between them and the flaps c, c" ofportions of the carton contents will be so minor, and so closelyconfined, as not to result in wicking of oil or grease, or penetrationof moisture or vapor, to a deleterious extent. In fact, portions of thecarton contents which thus enter will be so closely confined as to beheld against escape from such confinement and any wicking of grease oroil into the said endedges of the glue flap therefrom will be so minoras to present no problem.

In the modification shown in FIGS. 5 to 11, it will be seenthat theskiving of the longitudinal edge portion of the glue flap e is such thata continuous band of the paperboard is removed down to the linerprovided by the laminate j (FIG. 8), or the depth of the coating j (FIG.10), but preferably leaving some paper fibres otlstanding from theliner. Thus the liner provides an extension 3 (FIG. 8) or 3 (FIG. 10)which, after adhesive is applied to it and to the glue flap, will befolded over the raw or cut (skived) edge 4 (FIG. 8) or 4' (FIG. 10) andsecured to a longitudinal face portion of the glue flap, seeparticularly FIGS. 6, 9 and 11, thus serving to seal the said raw or cutedge. Here again, the presence of the adhesive saturated paper fibresoffstanding from the extension 3 or 3' will enhance the adhesive unionof the folded extension with the adjacent face area of the glue flap e.

As shown in FIGS. 12 to 15, and 18, the skiving is made to such a depththat the increment of paperboard removed is equal to one-half thethickness of the sheet and provides an edge extension 5 (FIGS. 12 and13) on the glue flap e which, when folded upon itself (FIGS. 14, 15.

and 18), will make the protected edge 6 of the glue flap the samethickness as the body of such flap, thus facilitating the folding of theglue flap and its adhesive securement against the inner face of thenarrow side wall 0 (FIG. 15) and presenting to the interior of thecarton an edge fully protected by the liner 1.

Alternatively, the skiving may remove an increment ex-' tending to theliner 1, and the edge extension 5' thus formed (FIG. 16) will be doubledback upon itself (FIG. 17). p

In these modifications (FIGS. 12 to 15 and 18, and 16 and 17) it will benoted that the bibulous paper fibres exposed by the skiving operation onthe extensions 5 and 5' will serve to enhance the adhesive bond betweenthe portions of the doubled extensions.

In the embodiment illustrated in FIGS. 19 to 22, the skiving operationis so performed and controlled as to produce a channel 7 spaced inwardlyfrom the raw or cut edge of the glue flap (FIGS. 19 and 20), and when,during the folding and gluing operation, adhesive is applied to the face8 of the glue flap such adhesive will fill the channel 7, as indicatedat 9, FIGS. 21 and 22. Thus, the adhesive at 9, which by its nature isoil, grease, moisture and vapor repellent, will provide a barrierbetween the raw or cut edge of the glue flap e and the broad side wall band will thus serve to arrest the passage through the fiap of oil,grease, moisture or vapor which, by wicking, absorption or penetrationmight enter the flap through its raw or cut edge.

The modification shown in FIGS. 23 to 26 is similar to that of FIGS. to11 insofar as the skiving operation is concerned, but instead of turningthe extension 1% (FIGS. 23 and 24) back upon the glue flap, as is donein the FIGS. 5 to 11 embodiment, it is adhered during the folding andgluing operation to the inner face of the narrow side Wall c (FIGS. 25and 26) thus sealing the raw, skived edge 11 of the glue flap againstwicking and ab sorption or penetration. It will be appreciated thathere, also, the presence of bibulous paper fibres on the surface of theextension 10, which is intentional as hereinbefore mentioned, will aidin securing a good adhesive bond between this extension and the cartonliner sheet or coating to which it is secured.

FIGS. 27 to 31 illustrate an embodiment of the skiving concept of theinvention in which, in addition to protecting or sealing the raw or cutedge of the glue flap e by an extension 12 similar in form and functionto those of FIGS. 1, 5, 12, 16, 23 and also 19, the first-folded endclosure flaps b, b" of the broad side wall b may be provided withextensions 13 which will fold over the longitudinal edges of these flapsand between them and the last-folded end closure flaps a, a", see FIGS.29 and 30.

To this end the flaps b and b are made of sufficient area to accomodateskiving along their longitudinal edges whereby the liner will be exposedto produce the exten sions 13. As shown in FIG. 31, this skivingoperation may preferably precede that which produces the skivedextensions 12, or fuctionally similar barrier means, on the.

glue flaps e. For example, as the flat blanks are fed along a platform14 in the direction of the arrows 15, as by lugged conveyor chains 16,rotary cutters 17, such as knived or abrosive wheels, will remove theproper increments of the respective end closure flaps b, b" to thusprovide the foldable extensions 13, and thereafter, upon transfer of theblanks to the platform 18, they will be fed in the direction of thearrows 19, as by lugged chains 20, at right angles to their formerdirection of feed, and into engagement with a rotary cutter 21,preferably similar to the cutters 17, which will remove the properincrements of their respective glue flaps e to produce the skivedextensions 12.

Thus, by a relatively simple adaptation of the folding and gluingmechanism, the step of skiving the glue flap may be accompanied by thestep of skiving the aforesaid end closure flaps, and the blanks canproceed from the glue flap skiving operation to the finalfolding andgluing steps to form the desired flat-folded, finished blanks.

In the embodiment shown in FIGS. 32 to 35 the invention is shown asapplied to a carton provided with a partition which is formed as anextension to the glue fiap and may be assembled therewith in properadhesive union with opposed carton walls when the carton blank isflat-folded and glued, but which is frangible from the glue flap whenthe flat-folded and glued blank is squared up or during the folding andgluing operation, thus enabling it to assume its carton-bodypartitioning location.

Having reference to FIG. 32, in which the inner, lined face of thecarton blank is shown, it will be seen that the blank comprises thebroad side walls a and b, and the narrow side walls 0 and d all providedwith their respective end closure flaps a, a; b, b"; c, c", and d, d,these 10 various elements being defined by appropriate customary cutsand folding scores.

As distinguished from the blanks shown in FIGS. 1, 5, 12, 19, 23 and 27,the blank of FIG. 32 has its glue flap e attached to the edge of thenarrow side wall d, instead of to the edge of the broad side wall b, andis joined on a line of rupture 22, such as a series of cuts and scores,or perforations, with a glue tab 23 to which is at tached on a foldingscore 24 a partition element 25 which carries on a folding score 26 aglue tab 27.

Bordering the line of rupture 22 the outer face of the glue flap e isskived to form a channel 28 similar to, and having the same function as,the channel 7 of the embodi ment of the invention shown in FIGS. 19 to22.

In folding and gluing this blank, adhesive is first applied to the innerface of the glue tab 23, as indicated by the stippling in FIG. 32, andthen the narrow side wall d and the glue flap e with its attached gluetab 23, partition element 25 and glue tab 27, are folded upon thefolding score 30 between the narrow side wall d and the broad side wallb flat against the inner face of the broad side Wall b, as shown in FIG.33, so that the glue tab will adhere to this broad side ball bsubstantially medially thereof. Then, with adhesive applied to the outerfaces of the thus disposed glue flap e and glue tab 27, as indicated bythe stippling at 31 and 32, respectively, in FIG. 33, with the adhesivealso filling the channel 28, the broad side wall a is folded on thefolding score 33 between it and the narrow side wall 0 flat against theglue tab 27 partition element 25 and glue'flap e, so that the glue tab27 will adhere to the inner face of the side wall a substantiallymedially thereof and the terminal edge portion of the side wall a willbe adhesively joined to the glue flap e. This final folding is shown inFIG. 34.

When pressure is applied to the opposite edges of the thus fiat-foldedand secured blank on the folds at the folding scores 36 and 33, as iscustomary, the blank will square up on these folding scores and on thefolding scores 34 and 35, and as it is thus erected the glue tab 23 willbreak away from the glue flap e on the line of rupture 22 so that theparts will assume the relative positions shown in enlarged section inFIG. 35.

It will be apparent, particularly by reference to FIG. 35, that theadhesive retained by the channel 28 will serve to seal the raw skivededge of this channel thus guarding against wicking, absorption orpenetration of oil, grease, moisture or vapor at such edge.

As hereinbefore stated, severance of the partition element 25 from theglue tab 23 along the line of rupture 22 may be accomplished during theoperation of folding and gluing the blank instead of as a function ofthe squaring up of the carton, and FIG. 36 depicts, schematically, onepractical manner in which this may be done.

As the blanks are continuously fed, inner face up, in the direction ofthe arrow h, a top gluer 1' applies adhesive to the inner face of theglue tab 23, and two underneath gluers j and k apply adhesive to theouter faces of the glue flap e and the glue tab 27, respectively, thegluer j serving also to fill the channel 28, all as shown at station I.Next, as shown at station II, the narrow side wall d, with its attachedglue flap e and partition elements 23, 25 and 27, is folded on itsfolding score 30, by a suitable plow or other conventional foldingmeans, over and down upon the broad side wall b, with a fixedlysupported rod or wire I interposed between this wall b and the glue flape, and rollers m and n, of which there may be aligned pluralities, serveto ensure an adhesive bond between the glue tab 23 and the wall b, andto holclthe blanks in proper feeding position.

It will be seen, also at station II, that the trailing end I of the rodor wire 1 (namely the far end thereof in the direction of travel of theblank) is curved, or bent, upwardly from the plane of the blanks, andthis serves to cause the rod or wire to automatically break the glueflap e away from the adhesively secured glue tab 23 ll along the line offracture 22 during feeding travel of the blanks, as indicated at stationIII.

Finally, the broad side wall a is folded on the folding score 33 by aplow or other conventional folding means, over, and down upon, thenarrow side wall c and the broad side wall b which positions it,flat-folded over the parts 23, 25, 2.7 of the partition element, withits free edge in adhesive engagement with the already adhesive-suppliedglue tab 27, whereafter, as the blanks pass beneath rollers n, o and p,preferably in aligned pluralities, the rollers and p will serve tomaintain bonding pressure in line with the glue flap e and glue tab 27,respectively, until the adhesive has set, all as indicated at stationIV.

. As thus assembled in fiat-folded condition, with the partition elementfreed from the glue flap e along the line of fracture 22 by action ofthe rod or wire l-l, and connected only to the broad side walls a and bby the adhesive union therewith of the glue tabs 27 and 23,

respectively, the fiat folded blank may easily be squared up with thepartition element disposed as shown in FIG. 35.

In the modified form of partitioned carton and blank shown in FIGS. 37to 42 the essential parts of the blank are the same as those of the formshown in FIGS. 32 to 35, but are, in some respects, differentlyassociated and hence dilferently folded and glued, as depicted in FIGS.38 to 42, and schematically represented in FIG. 43.

As shown in FIG. 37, the glue flap e is attached on a folding score 35'to the edge of the broad side wall a, as distinguished from the glueflap e of FIGS. 32 to 35 which is attached to the narrow side wall d,and the inter connected associated parts 23, 25', 27 of the partitionelement are attached by the glue tab 23' directly to the narrow sidewall at by a preformed line of fracture 22'.

In the folding and gluing of this modified form of blank, adhesive isapplied to the glue tab 23' on its inner face as indicated by thestippling at 29' (FIG. 37), to the glue flap e, pre-skived at 28, on itsouter face, as indicated by the stippling at 31' (FIG. 40), and to theglue tab 27', on its outer face, as indicated by the stippling 32'(FIGS. 38 and 39). With adhesive thus applied, either simultaneously orsequentially, as desired, the narrow side wall d with its attachedpartition element parts, is folded on the folding score 30 over and downupon the broad side wall b with the said partition element parts lyingfiat against such side wall and the glue tab 23' secured to themid-portion thereof by the adhesive 29' (FIG. 38). Next, the narrow sidewall d is separated from the thus adhesively affixed glue tab 23' alongthe line of fracture 22' and is turned back into substantially coplanarrelation to the broad side wall b (FIG. 39). Then'the broad side wall a,carrying the glue flap e is folded on the folding score 33 over upon thenarrow side wall 0 and against the partition element parts adhesivelyafiixed by the glue tab 23 to the broad side wall b, in which foldedassociation the glue tab 27' will be adhesively joined to themid-portion of the broad side wall a by the adhesive 32', and theadhesive-carry ing face of the glue flap e will be exposed (FIG. 4%).Completion of the folding and gluing operation entails merely thefolding of the narrow side wall d on its folding score 3% over upon thebroad side wall b with its free edge portion overlying and adhesivelysecured to the glue flap e (FIG. 41). Pressure applied to oppositevertical edges of the thus assembled blank (FIG. 41) will square itsparts up into the relative disposition shown in FIG. 42.

The schematic illustration in FIG. 43 of a method and apparatus forperforming the just described folding and gluing operation is similar tothat of FIG. 36 but modified for adaptation to the successive assemblysteps involved.

The blanks advance in the direction of the arrow g, and at station Iadhesive is applied by the top gluer r to the E2 inner face of the gluetab 23, and underneath gluers s and t apply adhesive to the outer faceof the glue tab 27' and to the outer face of the glue fiap 0',respectively, the gluer t serving also to apply the adhesive to theskived portion 28 of the glue fiap e.

As a blank approaches station II the narrow side wall (I with theattached parts 23', 25 and 27 will be folded by a plow or the like overa fixedly supported wire or rod 1; and down upon the broad side wall b,carrying with it over and against the said broad side wall the parts 23,25' and 27 of the partition element, and pressure rollers v will insurean adhesive bond of the glue tab 23' with the mid-portion of the saidbroad side wall. Further advance of the blank along the wire or rod u,the trailing end portion u of which is curved, or bent, upward, willserve to strip the narrow side wall d free of the afiixed glue tab 23along the line of fracture 22 and the said narrow side wall will beoutwardly folded, station ill, by a plow or other means intosubstantially coplanar relation to the body ofthe blank, station IV.

At station V the broad side wall a with attached glue fiap e is shownfolded on its folding score 33 over and down upon the narrow side wall 0and the parts of the partition element aflixed to the broad side wall bby the glue tab 23', thus bringing the mid-portion of the broad sidewall a into adhesive engagement with the glue tab 27, and pressurerollers v and w will insure adhesive bonds between the broad side wallsa and b and the glu tabs 27 and 23', respectively.

The final steps of the operation, namely the folding of the narrow sidewall d over upon, and the adhesive securement of its edge portion to,the glue flap e, is shown at station VI, and pressure rollers x will beemplayed for insuring a proper adhesive bond.

in FIGS. 44 to 46 there is shown a practical application of the practiceof the invention in combination with a preferred type of carton withwhich the sift-proof and infestation-proof method of the aforementionedHickin and McCullough invention (Patent No. 3,007,376) is employed.

The carton here shown is of the general type illustrated in FIGS. 1 to 4but includes a seal of the edge of the glue flap e which is similar tothat of FlGS. 5 to 11, or 12 to 17.

No contents are shown in the carton, but it is depicted ini FIG. 44 withits end closure flaps a, b, c and d closed and adhesively secured, andit will be apparent that the whole interior of the carton, including theedge of the glue flap 2, presents to the contents a surface completelycovered by the liner f and hence oil, grease, moisture and vapor proof,and not subject to wicking, absorption or penetration.

At the end edge of the closure flaps a and b, and of their opposite endcomplements a" and b", not shown, beads 36 of a plastic, normallynon-hardening, sealing compound are applied beneath the raised Van Burenears g (FIG. 44), and then these cars are closed down against andsecured to the adjacent narrow side walls c and a, (FIG. 45), thusconfining the sealing compound in sealing relation to any voids whichmight be present at such flap ends and thereby providing sift-proof,vermin-proof and moisture and vapor tight seals (FIG. 46).

For facility in breaking the seal, and opening the end closure, thenarrow side walls 0 and d may be provided with non-penetrating lines 37for their fracture adjacent to the edges of the Van 'Buren ears, so thatby pressing inward upon these ears the portions of the walls adhered tothem will break away.

In FIGS. 47 to 49 a further embodiment of the inven- 0 tion is shown, inwhich its practice can be particularly adapted to cartons of the outsideglue flap, or outside glue lap, type, or other types in which a raw edgeof a carton Wall, rather than a raw edge of a glue flap, is exposedinteriorly of the carton.

As shown in FIG. 47, the free edge of the broad side

1. THE METHOD FOR TREATING THE BIBULOUS FIBRES ADJACENT TO A RAW EDGEPORTION OF AN ELEMENT OF A CARTON BLANK FORMED FROM SHEET MATERIAL SUCHAS PAPERBOARD, WHICH COMPRISES THE STEPS OF: (A) REMOVING FROM SUCHEDGE-ADJACENT PORTION AN INCREMENT OF THE THICKNESS OF SUCH SHEETMATERIAL SUBSTANTIALLY IN THE PLANE OF THE ELEMENT AND LESS THAN ITS